It Report for

8/12/2019 It Report for

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INDUSTRIAL TRAINING

REPORT

LOCATION;

PELFACONIGERIA LIMITED

FROM;

1STAUGUST 2013

TO;

31ST

JANUARY 2014

REPORT SUBMITTED BY

DOUGLAS, BOMA PRINCE

UG/09/1368

DEPARTMENT OF CHEMICAL ENGINEERING

FACULTY OF ENGINEERING

NIGER DELTA UNIVERSITY, WILBERFORCE ISLAND, BAYELSA STATE

NIGERIA


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DECLARATION

I, Mr Douglas Boma Prince Wish to declare that all information contained in this

report are authentic and generated from first-hand experience as well as from

research carried out personally. Furthermore, I avoided direct lifting of information

from all referenced materials/books and lectures alike.


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DEDICATION

Whatsoever is worth doing is worth doing well Yoruba Adage

I dedicate this effort to;

To my Mum,

Whose love and support sustains me in everything that I do.

To my dearest Friends,

Who for believe in the path we follow have walked with me every step of the way, never

letting me fall behind.

Eno Edet Peter,

My motivation, always saying go. Youre the fuel to my furnace.


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ACKNOWLEDGEMENT

I would like to recognise the hand of God in all that took place in my life within the

period of my Industrial Training and appreciate his grace. For all the support I got

towards making my IT a success, the freedom of expression and creativity that was

availed me, a conducive and friendly working environment and most importantly

the continuous help and advice that I got for no charge, I remain ever grateful.

Mr Gesi Asamaowei

Engr Edward Orupabo

Engr Omega Pinnock

All staff at Pelfaco Head Office.


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TABLE OF CONTENT

i) Title Pageii) Declarationiii) Dedicationiv) Acknowledgement

Chapter 1.1.1 Introduction1.2 Brief history of Pelfaco Limited1.3 Mission Statement1.4 Key areas of Business and Service1.5 Company Organogram / summary of structureChapter 2. TUG BOATS AND BARGES

3.1 Tug Boats

3.1.1 Mode of Heat Exchange

3.1.2 Parts and Functions

3.1.3 Maintenance

Chapter 3. PIPELINES

4.1.1 Brief History of Pipelines

4.1.2 Process for Pipeline Installation

4.1.3 Pipeline Installation Procedure

4.2 Pipeline Doping

4.2.1 Pipeline Cathodic Protection

Chapter 4.

5.1 Conclusion

5.2 Limitations Experienced During SIWES Program

5.3 Suggested Improvements


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CHAPTER 1.

INTRODUCTION

After conclusion of lectures and examinations in April 2013, I as well as my

colleagues went to our various areas of industrial based training . After a few

months of disappointing outcomes, I was finally offered a place at Pelfaco Limited

to see out my allotted time of Six months.

Immediately I arrived at the office reporting for my first day on the job, I was

swiftly caught in the swing of events since the period of my arrival coincided withthe beginning of a project within the creeks of Rivers State. It involved a dredging

operation which the company was contracted to handle. I however will leave out

details of dredging operations since I was not privileged to experience such due to

my lack of the basic Safety requirements to be present at an offshore site at the

time.

Over the weeks I began to acquaint myself with the allotted tasks and the

staff present within the company as well. This further opened doors of knowledge

to me as relations with staff within the company became less formal and strained,

and we found ourselves easy to communicate with and understand.

Pelfaco Limited is an indigenous limited liability company set up in 1987 having its

first base in Rivers State. The initial establishment of the company was with the

idea of engaging in general contract operations. However, by 1994 the operations

of the company had become specialized in the area of engineering contract

management.

By the third week within Pelfaco, I was briefed by the administrative manager on

the planned routine I was to follow throughout my stay in the company. The

admin manager then asked me if I was satisfied with the arrangement. I took

advantage of the opportunity and requested he increase my time with the projects

team which was formerly scheduled for my Last Month of the industrial training.The schedule for my Industrial training was planned thus:


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Month 1: HSSE Department

Month 2: Document Control

Month 3: IT department

Month 4: Maintenance Department

Month 5: Maintenance Department

Month 6: Projects Department

Based on my request, I received an e-mail stating that my 5 thmonth would have me

doing rounds with the maintenance team to various sites, as would be requiredgiving me a chance to relate with project Supervisors and avail myself with all the

information I would need, even the same information that birthed this report.

A summary of my six months with the company

Month 1: HSE Department I obtained a swimming pass and PPEs to facilitate

future activities

Month 2: Document Control Gained an understanding of how important proper

documentation is to any organisations successful operation.

Month 3: IT Department- Java programming basics, Gained greater knowledge of

Desk Top internal components and handling.

Month 4: Maintenance Department- The workings of Tug boats, parts, handling,

dry docking. Barges of various types.

Month 5: Maintenance Department- Heavy equipment maintenance, Swamp

Buggy, Cranes, Bull Dozers, Freightliners, Pumps.

Month 6: Community relations, Pipeline installation, Pipeline welding basics.

An attempt will be made to capture all relevant (Engineering related) aspects of the

industrial training. However, some of these experiences only capture a minor

aspect of some broad fields and will not prove satisfactory for those who intend touse it for reference purposes.


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BRIEF HISTORY

Pelfaco Limited is an indigenous limited liability company set up in 1987 having itsfirst base in Rivers State. The initial establishment of the company was with the

idea of engaging in general contract operations. However, by 1994 the operations

of the company had become specialized in the area of engineering contract

management especially in the area of Oil and gas servicing.

PELFACO is a leading provider of the specialized services in the oil and gas

industry in West Africa. The organisation currently has operations at Pelfaco Jetty

(East), Minikpiti near (C.O.E),Rumuolumeni, Port Harcourt and

Pelfaco Base ( West), former Dumez yard, Eneheren Warri, Delta State.

The Base yard and jetty houses holds the fabrication and maintenance workshops,

materials warehouses, helipad, hangers, petroleum products storage facilities,

slipway and jetty facilities.

Pelfacosbusiness concern and clientele have expanded within the past yearsmaking them one of the major indigenous construction and dredging companies in

the oil and gas industry. The company's tremendous success is attributable to

efficient management decisions and foresight as well as a team of experts which

handle operations with high safety and equipment handing standards. This has

been confirmed true by various Multinational Oil and Gas companies as Pelfaco

has bagged many an award for their excellent HSE records.

MISSION STATEMENT

The mission of PELFACO LIMITED is to provide top quality Services on Land,

Swamp, and Offshore Locations for the Oil & Gas industry within the West and

central African Sub-Regions, while ensuring good corporate citizenship.


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KEY AREAS OF BUSINESS AND SERVICES

Pelfaco limited provides the following specialized services in the Oil and Gas

industry:

Land and swamp flow line /pipeline construction works includingconstruction of manifolds and support facilities.

Swamp pipeline works


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Fabrication servicesPelfaco Limited has undertaken over 30,000 tons of steel fabrication under

Erha and Okpoho platform fabrication project , and also the OB/OB Gas plant

revamp project these included: - Spools fabrication - Pipeline risers fabrication - Special (AFC) fabricated parts


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DREDGING AND SHORE PROTECTION

Sandfilling/land reclamation , canalisation, capital and maintenancedredging

PELFACO LIMITED HAS EXPERTISE IN Capital location dredging Sweeping /maintenance dredging Access and slot dredging Sand search/ geotechnical surveys Reclamation and sand stock piling Shore protection with steel sheets or concrete piles


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COMPANYS ORGANOGRAM

SUMMARY OF DEPARTMENTAL FUNCTIONS

MAINTENANCE DEPARTMENT - Headed by the maintenance Superintendent

Handles broken down equipment for the company both on and off worksites Routine checks on equipment Generation of regular Updates and reports on state of equipment

PROJECTS DEPARTMENT - Headed by the Projects Manager

On site work execution Design and assessment of project scope and methods Provision of reports to management on level of work done and project challenges.

HSE DEPARTMENT Led by the HSE manager

Insurance of Personnel Pre-mobilization qualification Ensure compliance of all staff to industrial safety standards Ensure safety equipment are in good working condition Perform drills to ensure consciousness of staff towards personal safety.

Managing Director

PRINCIPAL

ENGINEERADMINISTRATIVE

MANAGER

SECURITY

DEPARTMENTMAINTENANCE

TEAM

PROJECTS

TEAM

ACCOUNTS

DEPARTMENT

I T

DEPARTMENT

HSE

DEPARTMENT

DOCUMENT

CONTROL

LOGISTICS/

JOURNEY

MANAGEMENT


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IT DEPARTMENT Headed by the IT manager

Ensure proper Desktop and Laptop functionality within head office and Sites Maintain regular availability of wireless and Ethernet cable connectivity to Internet Manning of radio communication channels between Worksites and head Office as well as branch

offices.

Vessel CommunicationACCOUNTS DEPARTMENT Headed by the Chief Auditor

Payment of Salaries Funding of projects Balancing of company accounts Handling of staff welfare

SECURITY Headed by the Chief security Officer

Staff security within the offices as well as worksites Development of security plans for worksites Provision of security assessment reports

DOCUMENT CONTROL

Handling of contract documentation

Generation of project documentation Collection of Reports from all departments for record purposes Document support for all completed contracted projects

LOGISTICS

Vehicle and vessel permit/ certification handling Route selection for efficient journey management Car pooling and vehicle designation. Monitoring of transportation vehicles at worksites and offices.


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CHAPTER 2

TUGBOATS

TUG BOATS

A tugboat (tug) is a boat that manoeuvres vessels by pushing or towing them. Tugs move

vessels that either should not move themselves, such as ships in a crowded harbour or a

narrow canal, or those that cannot move by themselves, such as barges, disabled ships,

log rafts, or oil platforms. Tugboats are powerful for their size and strongly built, and

some are ocean-going. Some tugboats serve as icebreakers or salvage boats. Early

tugboats had steam engines, but today most have diesel engines. Many tugboats have

firefighting monitors, allowing them to assist in firefighting, especially in harbours.

There are basically two major types of tugboats;

1. The Seagoing Tugboats2. The River Tugboats

The design of these tug boats are slightly different as a result of the differing functions

they perform. Tugboats are highly manoeuvrable, and various propulsion systems have

been developed to increase manoeuvrability and increase safety. The earliest tugs were

fitted withpaddle wheels,but these were soon replaced by propeller-driven tugs.

At Pelfaco limited, both specifications of tugboats are available creating flexibility

of operations as required.

For purposes of this report, focus will be placed on heat exchange equipment aboard

Pelfaco owned Tug boats.
http://en.wikipedia.org/wiki/Paddle_steamerhttp://en.wikipedia.org/wiki/Paddle_steamer


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TUGBOAT KEEL COOLER

The keel of a Vessel is a lengthwise structure along the base of a vessel, in some cases

extended downwards as a ridge to increase stability. The keel extends along the base of

the vessel and makes direct contact with the waters below. This property makes it perfect

for the development of a shell and tube type heat exchanger.

The figure above also applies for fresh water regions. The keel cooler does not only

support the cooling of air conditioning systems, Tubes run from the engine room to the

hull of the tug boat conveying cooling water in a cycle. These cooling fluids lose heat on

making contact with the water interface beneath the vessel. This gives rise to a counter

current heat exchange.


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PARTS AND FUNCTIONS

Beloware some of the important characteristic parts of the tug boat and their functions;

1. Main mast, Mast headlight, flag, Siren These are in place for easy identification ofvessels from long distances, The mast headlight usually has a deep red penetrating

nature that travels long distances. Sirens could serve the purpose of alerting boats

that lay along the tug boats travel path of its approach.

2. Hawser; Popularly referred to as towing rope. These materials are of very highmechanical strength and can be used to immobilise the boat or in some cases aid

the towing of other vessels.

3. Bridge or Wheelhouse; An elevated room on the tugboat where the captain stays toMann the vessel and stir the vessel as well.

4. H-bitt Used in docking tug boat and ensuring it is not carried away by watercurrents that sweep through harbour.

5.

Hatch- These exist in two kinds, The void tanks and The crew rooms. The voidtanks are room for fluid and ullage handling in the tug boat while crew rooms may

include kitchens, engine rooms and the likes.


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6. Fender; The collision of Tug boats with cargo or other bodies can lead to someserious deformation of vessel structure. Hence, fenders are used to absorb shock on

impact and leave vessel in good order.

7.

Tail shaft, Propeller and Rudder- The tail shaft runs from the engine to the stern ofthe vessel transmitting torque. This torque transmitted is used to rotate a shaft

blade or propeller which displaces water creating a forward thrust for the entire

vessel. The rudder stands a short distance from the propeller lying in a streamlined

position. Displacement of the vessel wheel results in displacement of the rudder

which in turn causes the vessel to change direction with respect to direction of

wheel rotation.

8. Hull- The interface for vessel contact with water bodies, it is usually fitted withmany electrode plates to prevent rusting due to electrolytic reduction of metal

surface. The metal used as the sacrificial anode is usually Iron. Special care is taken

in sand blasting and coating this region with corrosion resistant paints.

9. Hydraulic pins- The day comes when the vessel will be out of order due to workinglong periods of time, the hydraulic pins serve to lift or tilt vessel for work to be

done on it. The process of lifting a boat out of water for maintenance purposes is

referred to as dry docking.

DRY DOCKING OF PELFACO TUG BOAT (LAGOS)


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CHAPTER 3

PIPELINING

Role of Pipelines

Energy needs to be transported from supply to demand Linking sources and markets for oil and gas is done using tankers and pipelines. Pipeline transportation is the safest method of delivering energy.At Pelfaco limited, fabrication and installation of industrial pipelines is a major source

of profit generation.

Abrief overview of the history of pipelines is outlined below

400 BC: Chinese used bamboo pipe to transmit Natural Gas to light their capital(Peking)

1800s: Wood, iron, lead and tin pipes were common in transporting gas to NewYork.

1859: River/Rail transportation in barrels by horse-drawn barges 1879: a 108 mile, 6 line was built to transport Natural Gas from Pennsylvania to

New York

1891: First high pressure, long distance pipeline was built. Transport cost reducedfrom $3/bbl to $1/bbl. Initially, pipelines were threaded together. This proved

difficult for large pipes and experienced leakage under high pressure.

1920s: Welding 1940s: Long Distance Pipelines the Big Inch(demands of 2ndWorld War).


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PRE-PIPELINE INSTALLATION PROCEDURE

The under listed, are the various considerations Pelfaco management and

contracting companies work through before setting pipelining activities underway.

Economic study Basic engineering and route planning Permission to build Land acquisition Setting out Bush clearing/grading

Without going through these procedures, community and Government officials

usually tend to be a problem and opposition to pipeline construction.

PIPELINE INSTALLATION PROCEDURES

Stringing At this stage, pipelines are distributed according to the design plan.This gives a clearer picture of challenges that lie ahead of the project that has

already begun. The stringing procedure is usually carried out by the swamp buggy

due to the nature of pipes being laid.Dis


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Welding The next stage is the beveling and welding of the strung pipeline.Bevelling involves trimming of pipe edges

This makes for available space to apply welding electrode to the piping. Pipeline

welding involves two major passes called Root pass and Hot pass.

The Root pass serves the basic function of filling up the bevelled portion of the pipe

with electrode material while the Hot pass is meant to seal up the weld and cause

welded portions to be in symmetry with circular pipe.

QA/QC (NDTs) After welding is done, for safety purposes, an NDT (Non destructivetest) is carried out. These tests exist in various forms. The basic function of the test is to

examine all welded joints on the pipe and ensure that there are no defects to the weld.

This is because such defects will cause possible leaks by the time the pipe is subjected

to stresses. The NDT carried out by Pelfaco limited is the Radiology test. In this

process, x-ray film is wrapped around the weld to be assessed and an x-ray is shot at

the coated weld. When this has been done for about 10 -15 minutes, the film is taken

for development and developed films are checked by a professional who may

recommend a joint be redone or pass a weld. The radiology is carried out in a lead

coated chamber for safety from radiation poisoning.

Ditching/Trenching When welding and NDT have passed successfully, Pipes arethen lowered into dug trenches in preparation for them to be done with. These

trenches are dug to specification usually with consideration of the sort of traffic the

pipeline right of way may experience.


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Back-filling This is the part where lowered pipelines are covered with back fillmaterials. The backfilling process is done with consideration of the kind of stresses

the pipeline may face. In areas where road surfaces may be built above piping,

backfilling is done in stages with tough materials which can stand such stresscausing a distribution on the overall stress acting on the pipeline.

Hydrotesting - As is the way of engineering, nothing is left to chance. The now laidpipelines are fitted with flanges on its end such that only one channel is left open.

At this point, the pipeline is flooded with water to a pressure above what the

pipeline is expected to carry (since pipelines are designed to handle higher

pressures than that anticipated). The pressurized system is left for about 24 hours

and the pipeline is checked for any signs of leak. If none is found, Pelfaco is happyand can breathe a sigh of relief.

These welding operations are usually carried out on a lay barge due to the marshy

terrain these operations are carried out.

LAY BARGE FOR PIPELINE ASSEMBLY


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(Pre-)Commissioning This stage involves site restoration. To keep the processenvironmentally friendly, once pipelining is completed, the company employs the

services of specialists to handle the aspect of reforestation and eco recovery (if

applicable). The major aim of this exercise is to leave the ecosystem in the samestate it was met or in an even better state.

Handover As it is with all contracts, at the point of pre commissioning, thecontracted company has fulfilled its contractual obligation and is ready to hand

over operations back to the parent company. This point involves payments and

accounting. Usually followed by a lot of paper work.

Other pipeline installation activities include

Pipeline Doping - This involves a system where a specialized corrosionprotective coating is applied over the welded regions due to the fact that

pipelines are designed such that their ends have open metallic uncoated

parts to facilitate welding. .This process is also known as sleeving

Cathodic Protection This is a technique used to control the corrosion of ametal surface by making it the cathode of an electrochemical cell. This could

be done in two ways

Sacrificial method characterised by;o Low soil resistanceo Small structureso Low current densityo Good coating

Impressed Current characterized by;o High soil resistanceo Large structureso High current densityo Poor quality coating

In pipeline cathodic protection, an external DC source is used to provide enough current

for the process to be effective.


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CHAPTER 4

CONCLUSION AND RECOMMENDATIONS

4.1 CONCLUSION

The Students Industrial Work Experience Scheme programme has provided me the

opportunity to acquaint myself with the practical procedures in solving industrial problems which

encompass various aspects of maintenance and pipeline installation, some of which could not be

captured in this report. The programme has been regarded as the most valuable exercise which has

exposed me to various aspects of learning and has broadened my horizon.

Also, the programme also afforded me the opportunity of reconciling the theoretical principles

learnt in school with real engineering design practice.

RECOMMENDATIONS

Based on the experience acquired, I humbly recommend the following:

Students should be given the opportunity to partake in this programme even for a longer periodof time.

Also the school authorities and departments should ensure that students are posted toplacements where they will gain skills and experience relating to their intended disciplines.

However, employers should be enlightened on the need to absorb students for the trainingbecause it forms a vital tool for the development of manpower in the country.

The management should be kind enough to provide safety materials for trainees during theirtraining.

The Institution supervisors should be adequately funded so that they can visit students in theirrespective SIWES workplaces.


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REFERENCES

1. Pipelines Rule of Thumb Handbook by E.W. McAllister 5thEdition2. Onshore Pipeline Engineering by Mike Ogbuanu3. Google Wikipedia4. Non-Destructive Testing Of Pipelinesby L. Annila

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